Assessment of different bio-inspired flow fields for direct methanol fuel cells through 3D modeling and experimental studies

The performance impact of using bio-inspired interdigitated and non-interdigitated flow fields (I-FF and NI-FF, respectively) within a DMFC is investigated. These two flow fields, as well as a conventional serpentine flow field (S-FF, used as a reference), were examined as possible anode and cathode flow field candidates. To examine the performance of each of these candidates, each flow field was manufactured and experimentally tested under different anode and cathode flow rate combinations (1.3 mL/min [methanol] and 400 mL/min [oxygen], as well as 2 and 3 times these flow rates), and different methanol concentrations (0.50 M, 0.75 M, and 1.00 M). To help understand the experimental results and the underlying physics, a three dimensional numerical model was developed. Of the examined flow fields, the S-FF and the I-FF yielded the best performance on the anode and cathode, respectively. This finding was mainly due to the enhanced under-rib convection of both of these flow fields. Although the I-FF provided a higher mean methanol concentration on the anode catalyst layer surface, its distribution was less uniform than that of the S-FF. This caused the rate of methanol permeation to the cathode to increase (for the anode I-FF configuration), along with the anode and cathode activation polarizations, deteriorating the fuel cell performance. The NI-FF provided the lowest pressure drops of the examined configurations. However, the hydrodynamics within the flow field made the reactants susceptible to traveling directly from inlet to outlet, leading to several low concentration pockets. This significantly decreased the reactant uniformity across its respective catalyst layer, and caused this FFs performance to be the lowest of the examined configurations.     

Performance tests of a double-passive μDMFC stack with parallel/dendrite flow field

We report an experimental study on the effect of different flow fields on the cell performance of a double-passive (both anode/cathode) μDMFC stack. Cell performance measurements were made and analyzed for seven different flow field combinations at the anode/cathode of a passive micro direct methanol fuel cell (μDMFC) stack. An optimum flow field combination, after taking a series of tests under different operating conditions, was obtained. The results show that the conventional parallel type flow field used at the anode with an innovative/new dendrite perforated type of 80° flow field can provide the best power density for both single cell and 8-cell stack which have a power density of 16.9 mA/cm² at 50 °C and 1 M methanol solution. Moreover, for an 8-cell stack, both the gravimetric and volumetric power densities can be up to 7.4 W/kg and 37.2 W/L, respectively.     

Study of novel flow channels influence on the performance of direct methanol fuel cell

The existing flow channels like parallel and gird channels have been modified for better fuel distribution in order to boost the performance of direct methanol fuel cell. The main objective of the work is to achieve minimized pressure drop in the flow channel, uniform distribution of methanol, reduced water accumulation, and better oxygen supply. A 3D mathematical model with serpentine channel is simulated for the cell temperature of 80 °C, 0.5 M methanol concentration. The study resulted in 40 mW/cm² of power density and 190 mA/cm² of current density at the operating voltage of 0.25 V. Further, the numerical study is carried out for modified flow channels to discuss their merits and demerits on anode and cathode side. The anode serpentine channel is unmatched by the modified zigzag and pin channels by ensuring the better methanol distribution under the ribs and increased the fuel consumption. But the cathode serpentine channel is lacking in water management. The modified channels at anode offered reduced pressure drop, still uniform reactant distribution is found impossible. The modified channels at cathode outperform the serpentine channel by reducing the effect of water accumulation, and uniform oxygen supply. So the serpentine channel is retained for methanol supply, and modified channel is chosen for cathode reactant supply. In comparison to cell with only serpentine channel, the serpentine anode channel combined with cathode zigzag and pin channel enhanced power density by 17.8% and 10.2% respectively. The results revealed that the zigzag and pin channel are very effective in mitigating water accumulation and ensuring better oxygen supply at the cathode.     

Development of a four‐cell DMFC stack with air‐breathing cathode and dendrite flow field

A four‐cell direct methanol fuel cell (DMFC) stack with an air‐breathing cathode with an active area of 0.48 cm² for each cell is designed, fabricated and tested. A pure copper sheet 300 µm thick with innovative perforated flow plates (dendrite type) is fabricated and used for the cathode. For the anode, conventional serpentine flow channels made of pure copper sheets 250 µm thick are used. An extensive parametric study is conducted to determine the optimum working conditions for the fuel flow rate (anode), methanol solution concentration, channel‐to‐land ratio and stack temperature. Comparisons are made with conventional serpentine flow channels. In addition, CO₂ (water) bubbles in the anode (cathode) channels are visualized, and the results are presented and discussed. It is found that the maximum stack power of the four‐cell μDMFC stack is up to 40 mW/cm² with a limiting current density of 335 mA/cm² at a maximum volumetric and gravimetric power density of 11.16 mW/cm³ and 3.13 W/kg, respectively. Copyright © 2014 John Wiley & Sons, Ltd.     

Water build-up and evolution during the start-up of a PEMFC: Visualization by means of Neutron Imaging

A commercial 50 cm² PEM fuel cell with serpentine flow fields was operated at 2.0 bar (a) and 60 °C with different relative humidity (RH) values for the inlet reactants (a matrix of 3 RH for anode and 3 RH for cathode). Between each test the cell was decompressed and liquid water was thus flushed out. The liquid water build-up and the time evolution during each experiment were recorded by means of Neutron Imaging. A qualitative and quantitative analysis of the results is presented in this work. It was observed that the dynamics of water build-up comprises three main stages, where the major difference is the liquid water accumulation rate. The onset location for the water appearance in the flow field channels was found to be determined by the flow field design, gravity and gas flow direction along the serpentine path. The time evolution of the water progressive accumulation along the flow field channels and cell active area is discussed.     

Investigation of mass transport and cell performance on μDMFC with different anode flow fields

The study systematically analyzes the performance of micro direct methanol fuel cell (μDMFC) with different flow fields. A two‐phase three‐dimensional model is developed to evaluate the mass transport accurately. The transport of methanol and air, the pressure distribution, the anode saturation, and the methanol crossover are numerically observed, the under‐rib convection is also investigated numerically. The flow fields with an active area of 0.64 cm² are fabricated on silicon wafers by micro electromechanical system technology. Performance of μDMFCs with different flow fields is sorted as: double‐serpentine flow field (DSFF) > single‐serpentine flow field (SSFF) > triple‐serpentine flow field (TSFF), and the dynamic test results indicate the cell with DSFF takes the shortest time to reach a stable power output when compared with other cells. Copyright © 2013 John Wiley & Sons, Ltd.     

Effect of flow-field pattern and flow configuration on the performance of a polymer-electrolyte-membrane water electrolyzer at high temperature

This study aimed to optimize the flow-field pattern and flow configuration of a polymer-electrolyte-membrane water electrolyzer, with a particular focus on high-temperature operation up to 120 °C. Three types of flow-field pattern (serpentine, parallel, and cascade) were tested in both the anode and cathode sides of a water electrolyzer cell, and the current-voltage characteristics and high-frequency resistance were measured to examine which overpotential components are impacted by the flow-field pattern. The experimental results revealed that the cathode flow-field pattern only affects the ohmic overpotential, while the anode flow-field pattern significantly affects the overpotential related to liquid water shortage at catalyst layer, and the flow configuration (counter- and co-flow) does not affect the electrolysis performance. Finally, under operating conditions of 120 °C and 0.3 MPa, we found that the optimized cell configuration consisted of cascade and serpentine flow-field patterns in the anode and cathode, respectively; this configuration produced the minimum electrolysis voltage of 1.69 V at 2 A/cm².     

Effects of cathode flow fields on direct methanol fuel cell-simulation study

Flow-field design of direct methanol fuel cell (DMFCs) plays an important role affecting the cell performance. Previous studies suggest that the combination of anode parallel flow field and cathode serpentine flow-field present the best and stable performance. Among these, cathode flow-field holds higher influence than that of anode. However, more detailed experiments needed to be done to find out the reasons. In this study, CFDRC half-cell models are adopted to simulate the flow phenomena within serpentine, parallel and grid flow field. We find that gas is well distributed within serpentine flow field while barren region are observed within parallel flow field. These factors contribute to the cell performance greatly. In addition, the durability test of DMFCs using parallel flow field is improved when the flow rate is increased or the current is uphold at inferior, so the barren region maintained at an acceptable level.     

Modification of graphite felt using nano polypyrrole and polythiophene for microbial fuel cell applications-a comparative study

Microbial fuel cells (MFC) are bio-electrochemical devices used for the generation of electricity from biomass. A single chamber membrane less air-breathing cathode microbial fuel cell (SCMFC) with two different anode configurations was investigated for energy generation using shewanella putrifaciens as bio-catalyst. The graphite felt (GF) anode was modified with 0.008 g/cc polypyrrole nanoparticles (Ppy-NPs) and 0.024 g/cc polythiophene nanoparticles (PTh-NPs) by conventional method. The nanoparticles coating improved the properties such as thermal characteristics and electron transfer capabilities of the anodes, which was confirmed by Thermogravimetric analysis (TGA), electrochemical impedance spectroscopy (EIS) and cyclic voltametry (CV). The variation in the cell potential with time under open circuit condition resulted in voltages of 0.842V and 0.644 V for Ppy-NP and PTh-NP modified GF respectively. A maximum power density (1.22 W/m²) was obtained for Ppy-NP modified GF than PTh-NP modified GF (0.8 W/m²). The results showed that GF coated with nano conductive polymers such as Ppy and PTh are the promising candidates for the best performance of a MFC.     

Effects of anode and cathode perforated flow field plates on proton exchange membrane fuel cell performance

The effects of both anode and cathode perforated flow field configurations on proton exchange membrane fuel cell performance are studied herein through electrochemical polarization techniques, electrochemical impedance spectroscopy, and cyclic voltammetry. The results demonstrate that serpentine flow field configuration in both anodes and cathodes is the best arrangement for cell performance (serpentine/serpentine, perforated/perforated, and serpentine/perforated). An electrochemical impedance spectroscopy examination shows that the serpentine/serpentine flow plate configuration results in a significant reduction in charge transfer resistance in a high current density (low voltage) regime. It further indicates that in a serpentine/serpentine flow pattern, a maximum electrochemical area is obtained with a higher Pt utilization of about 70% and is secured with full hydration at a cell temperature of 80°C. Finally, energy and exergy efficiencies analyses were also made. Data have been extracted and presented. Copyright © 2013 John Wiley & Sons, Ltd.     

Novel convergent-divergent serpentine flow fields effect on PEM fuel cell performance

A new design of convergent and divergent flow fields are being developed in single serpentine flow field pattern for proton exchange membrane (PEM) fuel cell. The channel depth is varied by means of inclination from inlet to outlet of the bipolar plate. By the varying inclined channel depth, it created convergent/divergent flow effect along the channel length in the single serpentine. Four different convergent flow fields are manufactured by the varying inclined channel depth from inlet to outlet as 1.5 mm–0.5 mm, 2.5 mm–1.5 mm, 3 mm～1 mm and 3.5 mm–0.5 mm, which are divergent flow fields as well by interchanging between inlet and outlet section. These convergent and divergent flow fields are compared with two conventional single serpentine having 1 mm and 2 mm constant channel depth for an active area of 4.7 cm². The experimental results showed that both convergent and divergent flow fields outperforms the conventional serpentine flow fields where maximum performance was achieved from convergent flow field C1 (1.5 mm–0.5 mm) improving 19–27% power than two conventional serpentine flow fields. Therefore this novel convergent serpentine flow field effect can improve PEM fuel cell performance by its suitable bipolar plate design.     

Effect of flow fields on the performance of micro-direct methanol fuel cells

This study evaluated the performance of micro-direct methanol fuel cells (DMFCs) with four kinds of flow fields fabricated on silicon wafers by microelectromechanical system (MEMS) technology. The flow fields and membrane electrolyte assembly (MEA) of 2.25 cm² active area were assembled to micro-DMFCs. These micro-DMFCs yielded the maximum power densities ranged from 11 to 23 mW cm⁻² for the methanol solution concentrations of 1 M, 2 M, 3 M, 4 M and 5 M at the temperature of 20 ± 1 °C. The maximum power densities implied that under the ambient temperature and low flow rate of methanol solution, performance of micro-DMFCs with different flow fields was sorted as: double-channel serpentine (DSFF) > single-channel serpentine (SSFF) > mixed multichannel serpentine with wide channels (MMFW) > mixed multichannel serpentine with narrow channels (MMFN) flow field. Increasing the flow rate of methanol solution from 0.0503 to 0.1128 ml min⁻¹, performance of all micro-DMFCs was improved. Further increasing the rate to 0.3479 from 0.1128 ml min⁻¹, the maximum power densities of micro-DMFCs with MMFW and MMFN increased, however, those of micro-DMFCs with SSFF and DSFF decreased. When the electric load was changed, the micro-DMFC with SSFF took a longer time to reach a stable power output than other micro-DMFCs.     

Enhancement of direct methanol fuel cell performance through the inclusion of zirconium phosphate

Nafion/zirconium hydrogen phosphate (ZrP) composite membranes containing 2.5 wt.% ZrP (NZ-2.5) or 5 wt.% ZrP (NZ-5) were prepared to improve the performance of a direct methanol fuel cell (DMFC). The influence of ZrP content on the Nafion matrix is assessed through characterization techniques, such as Thermogravimetric Analysis (TGA), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Electrochemical Impedance Spectroscopy (EIS), and water uptake measurement. Performance testings of the DMFCs based on these composite membranes as well as commercial Nafion^® 115 membrane were performed using a computer aided fuel cell test station for different values of cell temperature (40 °C, 60 °C, 80 °C, and 100 °C) and methanol concentration (0.75 M, 1.00 M, and 1.50 M). Characterization studies indicated that incorporation of ZrP into polymer matrix enhanced the water uptake and proton conductivity values of Nafion membrane. The results of the performance tests showed that the Membrane Electrode Assembly (MEA) having NZ-2.5 provided the highest performance with the peak power density of 551.52 W/m² at 100 °C and 1.00 M. Then, the performances of the MEAs having the same NZ-2.5 membrane but different cathode catalysts were investigated by fabricating two different MEAs using cathode catalysts made of Pt/C–ZrP and Pt/C (HiSPEC^® 9100). According to the results of these experiments, the MEA having NZ-2.5 membrane and Pt/C (HiSPEC^® 9100) cathode catalyst containing 10 wt.% of ZrP exhibited the highest performance with the peak power density of 620.88 W/m² at 100 °C and 1.00 M. In addition, short-term stability tests were conducted for all the MEAs. The results of the stability tests revealed that introduction of ZrP to commercial (HiSPEC^® 9100) cathode catalyst improves its stability characteristics.     

Three-dimensional analysis of a plate methanol steam micro-reformer and a methanol catalytic combustor with different flow channel designs

Three-dimensional models of a plate methanol steam micro-reformer and a methanol catalytic combustor with parallel flow fields and serpentine flow fields have been established. The effects of the flow field design and the fuel flow rate on the methanol conversion and transport phenomena in the micro-reformer were investigated. The results revealed that the methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field has been optimized as a result of improved thermal management in the micro-reformer with combustor. With a change in flow field design from the micro-reformer and the combustor with parallel flow fields to the micro-reformer and combustor with the serpentine flow fields a wall temperature increase from 225 °C to 237 °C was observed. The methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field could be improved by 23% relative to the employment of a parallel flow field. A numerical model provided an efficient way to characterize the transport phenomena within the micro-reformer and combustor; the results will benefit the future design of plate methanol steam micro-reformers with combustors.     

In situ comparison of water content and dynamics in parallel, single-serpentine, and interdigitated flow fields of polymer electrolyte membrane fuel cells

Water content and dynamics were characterized and compared in situ by simultaneous neutron and optical imaging for three PEM fuel cell flow fields: parallel, serpentine, and interdigitated. Two independent sets of images were obtained simultaneously: liquid water dynamics in the flow field (channels and manifolds) were recorded by a digital camera through an optical window, while the through-thickness integrated water content was measured across the cell area by neutron imaging. Complementary data from the concurrent images allowed distinguishing between the water dynamics on the cathode and the anode side. The transient water content within the cell measured using neutron imaging is correlated with optical data as well as with temporal variations in the cell output and pressure differentials across the flow fields. Water dynamics on both the cathode and anode side were visualized and discussed.The serpentine cell showed stable output across the current range and the highest limiting current. Parallel and interdigitated cells exhibited substantially higher water contents and lower pressure differentials than the serpentine. Anode flooding significantly impeded their performance at high current. At moderate current, cell output correlated with the changes in water distribution in the cathode flow field rather than with the variations in the overall water content. Performance of the interdigitated cell was similar to the serpentine one in spite of the vastly different water contents.The cell's water-content response to a step-change in current revealed three distinct stages of water accumulation. Flow field configuration greatly affected both the amount of water accumulated in the cell and the duration of each stage.     

A tapered serpentine flow field for the anode of micro direct methanol fuel cells

We develop a self-breathing micro direct methanol fuel cell (μDMFC) characterized by a new anode structure with tapered single serpentine flow fields to improve cell performance. Compared with the conventional single serpentine flow field, this new design enhances the methanol mass transport efficiency and the exhaust resultant (CO₂) rate due to the increasing pressure difference between adjacent flow channels. The μDMFCs with two single serpentine flow fields are fabricated using silicon-based micro-electro-mechanical systems (MEMS) technologies and are tested at room temperature. The experimental results reveal that the new tapered single serpentine flow field exhibits a significantly higher peak power density than that of the conventional flow field, demonstrating a substantial increase of 17.9% in mass transport coefficients.     

Numerical and experimental investigation on 25 cm2 and 100 cm2 PEMFC with novel sinuous flow field for effective water removal and enhanced performance

Commercial viability of fuel cells is limited as it does not produce the same power density while scaling and stacking, generation and safe storage of hydrogen is another snag. This work addresses water lodging at cathode (a scaling issue) through a novel sinuous flow field both numerically and experimentally, by scaling up of PEMFC from 25 cm² to 100 cm². Conventional serpentine flow field of 25 cm² widely studied in literature is experimented to validate the numerical model in a multiphysics tool. The model developed was applied to sinuous flow field of 25 cm² and the results revealed better water removal and 7.7% higher power density than serpentine flow field due to inter channel diffusion and under rib convection. In order to increase power density further the dwell time at anode has to be increased in sinuous flow field, hence anode side flow field was made serpentine while retaining sinuous flow field at cathode. This combination enhanced the performance the power density by about 14%. This serpentine-sinuous combination was then scaled to 100 cm² and experimented, revealing a lower power drop than serpentine flow field.     

Implementation and optimization of the HySyLab DMFC single cell test station

In this study, the construction and optimization of a low cost home-assembled DMFC single cell test station is described. The station was built using two flow control systems, for gas (air/oxygen) and liquid (methanol), a temperature controller, an electronic load, a milliohm-meter for resistance measurements and a computerized data acquisition system. The experiments were carried out on a 6.25 cm² single cell, built using two graphite plates with triple serpentine channel geometry for both anodic and cathodic flow fields. The cell was equipped with an MEA composed of Nafion 117 as electrolyte, Pt/C based catalyst as cathode and PtRu (1:1)/C as anode. In order to develop a HySyLab internal standard procedure, MEA activation was carefully studied. The activated MEA was used to determine the optimum values of cell operating parameters, such as oxidant flow, methanol flow and temperature.     

High performance ceramic nanocomposite fuel cells utilizing LiNiCuZn-oxide anode based on slurry method

A multi-oxide material LiNiCuZn-oxide was prepared through a slurry method as an anode for ceramic nanocomposite fuel cell (CNFC). The CNFCs using this anode material, LSCF as cathode material and a composite electrolyte consisting of CaSm co-doped CeO₂ and (NaLiK)₂CO₃ produced ～1.03 W/cm² at 550 °C due to efficient reaction kinetics at the electrodes and high ionic transport in the nanocomposite electrolyte. The electrochemical impedance spectroscopy revealed low ionic transport losses (0.238 Ω cm²) and low polarization losses (0.124 Ω cm²) at the electrodes. The SEM measurements revealed the porous microstructures of the composite materials at electrode and the dense mixture of CaSm co-doped CeO₂ and (NaLiK)₂CO₃. The Brunauer-Emmett-Teller (BET) analysis revealed high surface areas, 4.1 m²/g and 3.8 m²/g, of the anode and cathode respectively. This study provides a promising material for high performance CNFCs.     

Investigation on cold start of polymer electrolyte membrane fuel cells with different cathode serpentine flow fields

The flow velocity and pressure distribution of the three cathode flow fields are simulated in this study. Larger pressure drop and more rapid flow rate reduce residual water, resulting in minimal ice formation during the cold start process. The simulation results show that the single variable cross section serpentine flow field has the largest pressure drop and the most rapid flow rate.The evolution of the temperature and the segment current density characteristics of three different cathode flow fields during cold start process is studied by printed circuit board technology. The results show that the 2 to 1 serpentine flow field has the best cold start performance and the best current density uniformity when cold start at constant voltage mode above −5 °C. However, the single variable cross section serpentine flow field has the best performance when cold start temperature is below −5 °C. Based on these results, cold start at −30 °C can be realized in 97s by using hot antifreeze liquid.